Device for producing three-dimensional models and methods thereof

ABSTRACT

The invention relates to a device for producing three-dimensional models in a continuous process, comprising a build surface which has a first end in the direction of movement and a second end in the direction of movement, at least one dosing device and at least one solidification unit, characterized in that the build surface is designed to transport heavy components, and the components are transportable over the build surface essentially without distortion, and also comprising a method therefor.

CLAIM OF PRIORITY

This application is a continuation of U.S. patent application Ser. No.16/047,710 filed on Jul. 27, 2018, which is a continuation of Ser. No.14/400,957 filed on Mar. 13, 2015 which is a 371 of PCT Applicationserial number PCT/DE2013/000271 filed on May 17, 2013, and claimspriority therefrom. This application further claims priority from GermanPatent Application number DE102012010272 filed on May 25, 2012. Thecontents of U.S. patent application Ser. Nos. 16/047,710 and 14/400,957,International Patent Application PCT/DE2013/000271 and German PatentApplication DE102012010272 is each incorporated herein by reference inits entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a system for the continuous productionof three-dimensional models on a horizontal transport device, using alayering technique.

PRIOR ART

In layering methods used today for producing three-dimensional objectsbased on computer data, methods are used in which a platform (buildingplatform), which is movable at least in the vertical direction andwhich, if necessary, is surrounded by a container and thus forms a jobbox, is placed in an uppermost position at the beginning of the process.A build material, for example a substance in the form of particulatematerial in the case of 3D printing or laser sintering, is then appliedin a thin layer over the entire area of this platform. In another step,the material is selectively bound with the aid of a physical or chemicalsolidification mechanism according to the desired component shape. Thisbinding step may take place, for example, using adhesives, which may beprinted with the aid of ink jet techniques. The platform is then loweredby one layer thickness, and a new layer of particulate material isapplied.

These steps are repeated until the desired body is built, i.e., allnecessary layers have been applied and solidified. The container issuccessively filled with particulate material during these steps, partsthereof being bound to the desired structural body, while the restremains loose and is used during the building process as a supportmedium for overhanging parts of the object to be built.

After completing the layering process, following a waiting period whichmay be necessary, the loose particulate material may be extracted orremoved in another manner and the desired object discharged.

It is possible in this case to produce components continuously using anendless, horizontal layer feed.

In conventional systems for building models in layers, the componentsare produced vertically in layers from top to bottom.

When the maximum build height of a system is reached, the buildingprocess must be stopped in order to subsequently remove the componentsin the system and thereby create space for a building process, oranother build frame must be inserted with the aid of a changing systemin order to be able to thereby start a new building process. As aresult, the construction of components is limited with respect to sizeand productivity.

In the known “continuous 3D printing” method, the layer feed takes placein the horizontal direction, e.g., on a continuous conveyor belt.

Gravity prevents a layer to be applied perpendicularly to the layerfeed, which is why the individual layers are applied at an angle. Theangle is selected in such a way that it is smaller than the specificangle of repose of the corresponding particulate material.

The layering process is followed by an enclosed conveyor line, whoselength is adapted to the method-dependent hardening duration. At the endof the conveyor line, the finished components enter a removal area.There, the components are freed of unbound particle material and removedwithout having to interrupt the production of additional parts.

In the continuous method, different tools and methods may be used tofeed the components, for example continuous conveyor belts are used.

Continuous conveyor belts are generally closed belts made of a flexiblematerial (e.g., woven fabric) that is looped around a drum at each endto reverse the direction of travel. At least one of the two drums drivesthe conveyor belt. Between the drums, the belt must be pulled over asupporting surface to avoid sagging. Above a certain width of theconveyor belt or above a certain mass of the particulate materialfeedstock, the frictional engagement between the conveyor belt and thesupporting surface is so great that stick/slip effects may occur, or thedrive may fail completely.

Link conveyors are furthermore known, which are able to accommodate veryhigh loads. Link conveyors of this type are driven in the same way asconveyor belts. A drive drum or return drum is located at each end ofthe closed link conveyor. If a link conveyor is driven in this manner,an uneven feed results. This is because the plates unwind in the mannerof a polygon. At the same time, the bearing of the individual links mayprove to be sensitive to contaminants. If the links do not ideally abuteach other, build material may enter the space between two plates viathe joints and impair the operation of the flexible connection. Inaddition, particulate material may be lost uncontrollably via the joint,which may result in defects in the particulate material feedstock andthus in the components.

Link conveyors are an additional option. Link conveyors are able toaccommodate high loads and are driven in the same manner as conveyorbelts. A drive drum or return drum is located at each end of the closedlink conveyor. If a link conveyor is driven in this manner, an unevenfeed results. This is because the plates unwind in the manner of apolygon. At the same time, the bearing of the individual links may proveto be sensitive to contaminants. If the links do not ideally abut eachother, build material may enter the space between two plates via thejoints and impair the operation of the flexible connection. In addition,particulate material may be lost uncontrollably via the joint, which mayresult in defects in the particulate material feedstock and thus in thecomponents.

The use of individual plates which are fed in a feed unit from amagazine is also known. In this case, the build time is dependent on thenumber or length of the individual plates. Continuous building ispossible only if the building platforms are automatically returned tothe magazine at the end of the building process. This is technologicallycomplex, since the plates must, among other things, be clean for reuse.The vibration-free and dense placement of a new plate has also proven tobe difficult. The concept of this building device must furthermore bechanged to the extent that the coater is no longer able to travel underthe level of the build plane.

The known feeding means for use in a continuous process for buildingbulky and complex models (components) in layers are thus subject to alarge number of problems. Up to now, no devices and methods are knownwhich are suitable for producing large and heavy models and which avoidthe disadvantages described above.

A need thus exists for providing a device and a method for buildingmodels in layers by means of which large and heavy components may beproduced, preferably in the continuous process, and which are consistentwith a preferably precise satisfaction of the requirements, or by meansof which the disadvantages of the prior art may be at least improved oravoided entirely.

PREFERRED EMBODIMENTS OF THE INVENTION

The invention relates to a device for producing three-dimensionalmodels, preferably in a continuous process, comprising a build surfacewhich has a first end in the direction of movement and a second end inthe direction of movement, at least one dosing device and at least onesolidification unit, characterized in that the build surface is designedto transport heavy components, and the components are transportable overthe build surface essentially without distortion. In preferredembodiments which provide a rotational operation, the first end isunderstood to be the start of the process, and the second end isunderstood to be the end of the process, or preferably the unpackingposition or the unpacking operation.

The inventors have advantageously succeeded in providing drives whichare suitable for producing bulky and heavy components, in particular incontinuous processes, for building models in layers using inclinedprinting, and which facilitate precise production without distortion incompliance with the requirements.

The inventors thus have developed a device and a method, by means ofwhich particularly heavy components may be precisely produced in thecontinuous layering method (inclined printing) and which avoid or atleast significantly improve the disadvantages of the prior art. In onepreferred embodiment, the work takes place in batches.

As illustrated above, different options exist for transporting theparticulate material strand. However, the systems all have seriousproblems with regard to precision of the movement under heavy loads. Aconveyor belt must thus be guided over at least two return rollers, thedrive being reasonably integrated into the rear return roller in theconveyance direction. The movement precision of the belt would behighest in this location and correspondingly lowest at the other end,due to slackness in the belt. However, this is where the layering iscarried out, i.e., the very place where the belt movement must beprecise.

With the aid of the device according to the invention and the methodaccording to the invention, it is now possible to move the feedstockcompletely forward and to achieve a distortion-free, precise feed whenproducing heaving components. Disadvantageous distortions due toslackness in the drive, which occur in known methods and systems usedtherein, are advantageously avoided with the aid of the invention. Theprecise production of heavy components by means of layering in thecontinuous process is made possible hereby.

In preferred devices according to the invention, the build surface is ahorizontal, continuous and/or open conveyor belt, or it is designed as arotating platform or a step conveyor.

The build surface—and thus, in particular, the model or component—ispreferably conveyable with its first and second ends essentially at thesame speed and with the same feed.

A particularly preferred device is characterized in that the deviationin the feed between the first and second ends of the building platformis less than 1 mm, preferably less than 0.5 mm, most preferably 0.3 mm.

Preferred devices according to the invention may be characterized inthat the conveyor belt rests and runs on continuous and/or lateralrollers.

A device according to the invention may furthermore be characterized inthat the conveyor belt has at least one central support, the supportpreferably comprising air cushions and/or friction bearings and/orrollers and/or ball casters.

The conveyor belt may have individual links, preferably connected byhinges, the links having gripping elements which are driven by worm gearor guide mechanisms.

The gripping elements may be gripped and positioned with the aid ofhorizontally positionable or oscillating or rotating grippers and/orbarbed hooks and/or magnets and/or vacuum grippers.

One area of the conveyor belt may be transported on a liftable base bymeans of frictional engagement or cohesion of solid bodies.

The conveyor belt is preferably driven by at least one continuous rolleror on both sides by at least two lateral rollers.

In another preferred device, one area of the conveyor belt istransported by means of magnetic fields.

It is also possible for the building platforms of the device to beautomotively driven, preferably on overhead rails or free-moving.

The hinges contained in the device preferably have only limited mobilityperpendicularly to the conveyance direction.

Roller tracks are preferably added to the device.

The device according to the invention is particularly preferablycharacterized in that a horizontal, movable build surface for applyingbuild material is provided, and a build space is disposed around it, onwhich at least one dosing device for particulate material and asolidification unit for particulate material are mounted via linearguides, and the horizontal build surface [is provided] in a Z direction,i.e., at a certain angle to the transport device which is smaller thanthe angle of repose of the build material. The angle is preferably <30degrees.

Another aspect of the invention is a device referred to as a “coneprinter” for building components. Its functionality is apparent, inparticular, from FIGS. 10a through 10 c.

A cone printer in the sense of the invention is able to build componentson a building platform in a rotating and outwardly directed motion fromthe inside to the outside by layering particulate material.

The production of components takes place according to the 3D method,i.e., a layer of particulate material is applied in the first step, anda selective solidification of the particulate material takes place inthe second step in the known manner. The application of particulatematerial takes place continuously, a coater (1) completing a circularpath for layering the particulate material. The solidification unit (2)follows this path of the coater (1) and ensures the selectivesolidification of the particulate material and thus the production ofcomponents.

A plurality of components may be advantageously produced on one buildingplatform simultaneously or in batches.

The building platform may be selected in dimensions that allow heavycomponents to be produced. This preferred design thus also achieves theobject of a distortion-free production of multiple components.

The special advantage of the use of a cone printer lies in the fact thatlarge and heavy components may be produced without distortion, and aplurality of components may be produced with a high degree of precisionin batches.

The invention furthermore relates to a method for producing threedimensional models in the continuous process, comprising the followingsteps: a. building the model in layers on a building platform in a firstposition, a first layer being applied; b. transferring the model fromthe first position to a second position with the aid of a feed after alayer is built, the building platform, which has a first front end and asecond rear end, being transported with the model; c. building anotherlayer on the model on the building platform; d. transferring the modelon the building platform to another position; repeating steps a.)through d.), the transfer preferably being carried out by means of astep conveyor, the step conveyor preferably having lifting and thrustinggrates.

In the method according to the invention for producing three-dimensionalmodels, the model on the building platform is transferred withoutdistortion from the first position to the second position.

The method according to the invention for producing three-dimensionalmodels is characterized in that the building platform with the model isevenly transferred from the first position to the second position andany further position essentially without deviations in feed between thefirst and second ends of the building platform.

The deviation in feed between the first and second ends of the buildingplatform from the first position to the second and any further positionis preferably less than 1 mm, preferably less than 0.5 mm and mostpreferably less than 0.3 mm.

When producing large and heavy components, in particular, therequirements of the horizontal transport device of devices for thecontinuous method are particularly critical in order to achieve adimensionally accurate and precise reproduction in the component.

In this case, a loosely applied feedstock made of sand or particulatematerial must be positioned a few micrometers (e.g., 80 μm) with eachnew layer. The feedstock has only a limited stability and may weighseveral tons.

The device according to the invention or the conveyor system accordingto the invention is preferably characterized by one or all of thefollowing characteristics:

-   -   Continuous feed (continuous conveyor)    -   Vibration-free feed    -   High positioning accuracy in the range of just a few micrometers        (e.g., 1 μm)    -   High rigidity in the conveyance direction under high loads        (tensile loads up to several tons)    -   High rigidity in the vertical direction (weight load up to        several tons)    -   Resistance of the supporting surface to contamination with the        build material (e.g., abrasive sands/particulate material or        aggressive solvents)    -   Density of the supporting surface in order to prevent runoff of        the build material.    -   No stick-slip effects    -   Minimal maintenance with almost non-stop operation    -   Cost-effective construction

The present invention advantageously combines the aforementionedcharacteristics or at least a subcombination thereof and thus providesan advantageous device and a method for building models in layers, thedisadvantages of known devices and methods being avoided or at leastpartially improved.

In particular, with regard to load tolerance and positioning accuracy,the invention provides a superior device and method.

The device according to the invention may be used, for example, toproduce casting molds from molding sand, in which the dimensions andthus the weight of the particulate material feedstock are particularlyhigh.

One approach according to the invention lies in the use of linkconveyors. Link conveyors whose individual links are connected byspecial hinges are particularly suitable in this case. The hinges have astop which results in the fact that the link conveyor is able to bend orroll off from the plane in only one direction (downward in this case).It is rigid in the other direction (upward in this case). A sagging ofthe link conveyor is prevented thereby, and an even feed with onlyslight deviations or only slight distortion is achieved.

In one particularly preferred embodiment, this link apron is laid over aroller track and driven by friction engagement. The roller track is anarrangement of multiple rollers or cylinders. One, multiple or allrollers may be driven. If all rollers are driven, an even feed of thelink conveyor results. Since the entire build space of the link conveyoris driven, the belt does not undergo any tensile loading. The belt isthus unable to lengthen during operation, and stick-slip effects areruled out. If the link conveyor has play in the hinges, this does nothave any negative effect.

This type of drive also ensures an exact positioning, since the drivetakes place at the point where the plates have already achieved ahorizontal alignment. A polygon effect, which occurs in known systems,does not take place in the invention.

The individual rollers or cylinders may be preferably synchronized bymeans of coupling elements such as toothed belts, driving belts, chains,toothed wheels or worm gears. If the rollers are connected by drivingbelts, toothed belts or chains, the link conveyor may also rest directlyon the driving belts, toothed belts or chains. Particularly wide beltsrequire rigid cylinders or cylinders having a large diameter forsupport. As the cylinder diameter increases, so does the distancebetween the individual cylinders. Link aprons having low intrinsicrigidity could sag between the cylinders.

It may thus be reasonable to attach the drive only to the sides of thelink conveyor and to separately support the free-hanging links betweenthe side drives.

All rigid supporting surfaces having good sliding properties aresuitable as the support. These may be, for example, the following parts:

-   -   Roller tracks    -   Ball tracks    -   Sliding materials (e.g., plastics, non-ferrous heavy metals)    -   Air cushions    -   Hydrodynamic bearing of the individual links    -   Hydrostatic bearing of the individual links

In principle, it is also possible to equip each of the links withrollers or ball casters.

To improve the static friction, the rollers may also be pressed onto thedriving rollers with the aid of lateral rollers. The rollers may also bedesigned as toothed wheels. In this case, the individual links also havea tooth profile with which the driving wheels may engage.

If a link conveyor is used, it is also possible to equip the undersideof individual or all links with a round driving element, for example.The driving element is then gripped with the aid of a worm gear or aguide wheel and advanced by the necessary layer thickness.

If the individual links are equipped with a driving element, it is alsopossible to use a reversing linear drive, which repeatedly grips andpositions the driving element by means of a gripper. This device may beprovided with a particularly rigid design using simple means.

In principle, a spring-supported barbed hook may also be used instead ofan active gripper, similarly to a one-way bearing.

Switchable vacuum grippers or magnets or hook-and-loop fasteners arealso suitable. They may also be inserted in such a way that they engagewith the belt in a rotating or oscillating manner. A preferred positionwould then be within the chain.

A particularly preferred embodiment of the invention lies in the use ofa discontinuous conveyor line with the aid of a step conveyor. Thetransported material is moved along the entire length in discrete steps.One preferred form of a conveyor mechanism of this type includes a leversystem in the form of a four-bar linkage, which is driven in a rotarymotion at one of the linkage points. A rigid supporting surface issituated on the side at a distance from the lever mechanism. Themovement sequence begins with the resting position of the transportedmaterial on the supporting surface. When the four-bar linkage rotates, alever of the device will receive the load of the transported material,lift the transported material and place it back down on the supportingsurface after a discrete distance has passed. The transported materialmust travel a horizontal distance on the supporting surface before theprocess starts over.

In the sense of the invention, “step conveyer” is to be understood asfollows: a model or component is built in layers and transferred from afirst position to a second position with the aid of a step conveyordevice, this process continuing or being repeated in steps, and thecomponent thus being subjected to step-by-step layering. It is possiblethat the process takes place in a longitudinal direction. Alternatively,the step conveyor device or the method may be designed in such a waythat a repetition of the transfer from position 1 to position 2 and thenback to position 1, etc., takes place. According to the invention, thestep conveyor may be used to transfer the components, which have aweight of several hundred kilograms to several hundred tons, withoutdistortion. The feed of each transfer may be from several centimeters toseveral meters, depending on the device and the method of the layerbuilding method. The feed or transfer speed may be 0.5 to 20 m/min. or0.1 to 15 minutes per cycle. The step conveyor may have a fixed frame,including guide rollers, a mobile frame on lifting rollers and a drive.The drive may have a mechanical, pneumatic or hydraulic design for thepurpose of achieving the feed or the lift. For example, the mobile frameis lowered at the start position and the building plate with the modelto be constructed is lowered onto the fixed frame with the aid of, e.g.,hydraulics (a first position) and moved forward in one direction inorder to be lowered again after the transfer (a second position). Thisprocedure may then be repeated cyclically. The building plate is liftedand lowered again at the start and end of the direction of movement. Thetransfer process may be controlled from a central unit, e.g., acomputer, and be coordinated with the other components and work stepsfor layering the component, such as application of layers and selectivesolidification or selective application.

The advantages of an approach of this type lie in a simple structure ofthe conveyor system, the ability to support and to move the transportedmaterial over the entire length. In addition, the structure may bedesigned to be extremely resistant to sagging due to loading by theweight of the transported material.

If multiple lever systems of this type are built next to each other,loads of greater width may also be reliably conveyed. The onlyrequirement for the transported material: it must be stiff enough tobridge the distance between the lever systems in a freely supportedmanner. Flexible or fragile transported materials may also betransported with the aid of carrier systems such as palettes. If thetransported material is to be moved horizontally without any verticalmovement, the lever system may be equipped with linear actuators insteadof the rotatory drive. In other words, the transported material againrests on a lever. Another lever moves against the transported materialperpendicularly to the conveyance direction. The first lever is thenlowered, and the second lever receives the load and shifts it by adiscrete length in the direction of conveyance. The first lever then israised again against the transported material and receives the load,while the second lever is lowered in order to move back into the initialposition. To distribute the weight load better, a lever system of thistype may comprise multiple levers situated side by side, which mesh witheach other like two grates. Since the levers should have a certaindistance from each other for reasons of reduced friction, a coveragemust take place over the gaps between the levers if the transportedmaterial has small components, as in this case. This may be achieved,for example, by laying down a foil. If the transported material is ahigh-density particulate material, as in the present case, the foil mustonly be tensile, since the force of the weight is sufficient to hold thefoil in position. The foil may be guided continuously over the device inthe form of a belt as well as at the two ends of the device with the aidof foil rolling and unrolling mechanisms.

In another preferred embodiment, the sealing takes place via a linkapron, which is guided over the lever mechanism.

A lift/thrust device made of two liftable grates has proven to beparticularly advantageous for transporting a link apron or a conveyorbelt.

A grate is assembled from parallel plates or rods which are oriented inthe feed direction.

At least two grates engage with each other in such a way that each grateis positioned vertically and is able to carry the link apron. At leastone of the two grates must be positioned in such a way that it may bemoved in the feed direction.

During the building process, both grates are extended all the way withthe aid of linear actuators (e.g., pneumatic cylinders, spindles), sothat they are situated at the same height and both carry the conveyorbelt (link apron). For transporting, one grate moves down, so that theonly grate carrying the conveyor belt (link apron) is the one which isable to position it in the feed direction by means of another actuator(thrusting grate). Once the grate has positioned the conveyor belt (linkapron) in the thrust direction, the other grate (lifting grate) movesout. When the lifting grate comes to rest, the thrusting grate movesdownward again and subsequently returns to its vertical startingposition.

In principle, the repositioning of the thrusting grate may also takeplace in the thrust direction after multiple individual steps, if thetraveling distance of the linear actuators permits this. In this case,the thrusting grate is lowered and returned to the starting positiononly after multiple individual steps have been completed. This proceduremay be advantageous for the purpose of reducing positioning errors,e.g., due to the reversing play of the linear actuators.

This system is absolutely rigid with respect to a conveyor belt, andprecise positioning may take place simultaneously in both feeddirections.

Another advantage of the system lies in its easy scalability, both inthe feed direction and also transversely thereto, e.g., by widening thegrates or arranging multiple systems in a row.

The structure may preferably have grates, and it is also possible tolift only the thrusting grate or a thrusting platform by a minimalamount. Minimal lifting in this case means lifting the thrusting grateor a thrusting platform only until the force of the weight produces thecorresponding frictional engagement between the thrusting grate and theconveyor belt. The thrusting grate or a thrusting platform subsequentlypositions the conveyor belt horizontally. If the conveyor belt sagstransversely to the conveyance direction, it may, under certaincircumstances, fail to be fully lifted. The remaining supporting areasare then preferably designed to have good sliding properties. In theseareas, air cushions or rollers may be mounted on the link apron itselfor on the supporting surface.

Conveyor belts which are driven by means of frictional engagement or aform fit (similarly to a toothed belt) are also suitable up to a certainwidth. It would also be possible to incorporate driving elements into aflexible conveyor belt. Electrically conductive windings, which areincorporated into the belt, would also be possible, so that the entirebelt is driven by means of self-inductance, similarly to a three-phasemotor.

To avoid sagging in particularly wide belts, intrinsically rigid insertsmay be incorporated transversely to the feed direction.

Another option according to the invention is to apply the particulatematerial feedstock on individual plates. The plates could be moved withthe aid of the same transport systems as for link conveyors (see above).For continuous building, the transportation of the built-upon platesback to the start after unpacking must be ensured. This may beaccomplished with the aid of robots or conveyor belts.

However, it is also possible to transport the individual plates on arail system.

The plates may be supported individually, e.g., on rollers or aircushions, and transported into the system.

For automation, each plate may be equipped with its own intelligentdrive. All information on the particular building project may be storedtherein, and it may communicate with the building device and thewarehouse.

The methods described above may also be used for conveyor belts and linkconveyors which are rolled off of and onto rollers. A design of thistype advantageously permits uninterrupted operation.

To store as many parts as possible, spiral conveyor belts may also beused, similarly to those in spiral freezers.

In principle, both open and closed belts in the form of foils or sheetsmay be used to seal link aprons. These sealing belts may be inserted byrollers in an open or closed manner.

Rotating plates, on which the material cone is applied tangentially, arealso conceivable.

It would also be possible to produce a truncated cone on a rotatingplate. The coater and the tool for selective solidification (e.g., theprint head) move axially away from the rotation axis synchronously withthe rotary motion of the plate.

In one particularly preferred device or method for producing componentsby 3D printing, according to the invention, a coater and asolidification unit for selective solidification are combined with acircular building platform (see FIG. 12). The first end and the secondend are to be understood in such a way that a process start exists(first end), at which the particulate material application takes place,and a process end exists (second end), at which the component isfinished or the finished components are preferably unpacked. Theselective solidification may take place in the process with the aid ofchemical methods (selective solidification with the aid of a chemicalbinder) as well as using methods such as selective laser sintering orlaser melting (SLS, SLM). The circular building platform may also becombined with devices for the selective application of material, such asFused Deposition Molding (FDM) and other methods known to those skilledin the art for the selective application of material to predeterminedareas.

This preferred device according to the invention or the productionmethod have the further advantage that the components are produced on asingle rotating building platform, and the component thus does notchange its position on the building platform, whereby the productionalso takes place without distortion. This is advantageous, inparticular, when producing large and heavy components. The method may becarried out in batches or continuously. During continuous operation, amethod step of a continuous unpacking operation, using means which areknown to those skilled in the art, is combined with other device partsand method steps and coordinated therewith.

DESCRIPTION OF THE FIGURES

FIG. 1 shows a preferred structure according to the invention, includinga closed conveyor belt (e.g., link conveyor) (7) and an open sealingbelt (6). The conveyor belt is able to bear the great weight of theparticulate material cake while the cover belt is being unrolled andshould only prevent the conveyor belt from coming into contact with theparticulate material cake. The conveyor belt is unrolled from a rollerand rolled up again behind the conveyor belt. The cover belt may be fedby means of frictional engagement on the conveyor belt or by winding up.

The device for producing the three-dimensional models may include atunnel, such as illustrated in FIG. 1. The build apparatus may applybuild material to the feedstock before the feedstock enters the tunnelwith a dosing unit. Preferably the feedstock is conveyed through thetunnel in a conveyance direction 17. The tunnel may be formed by walls4. Preferably the tunnel has a side wall 4 having an edge 37 that isangled relative to the conveyance direction 17 and is angled relative toa direction perpendicular to a surface of the conveyor. Preferably, thefeedstock 3 fills the entry opening of the tunnel 38, such asillustrated in FIG. 1.

The coater 1 preferably applies the particulate material directly to thefeedstock 3, such as illustrated in FIG. 1. The coater 1 may move onlinear guides 8, such as illustrated in FIG. 1. The coater 1 preferablyis outside of the tunnel 38, such as illustrated in FIG. 1. The linearguides 8 are preferably outside of the tunnel 38, such as illustrated inFIG. 1. The tunnel 38 preferably at least partially supports thefeedstock 3, such as illustrated in FIG. 1.

FIG. 2 shows a preferred link conveyor according to the invention,including hinges which permit mobility only in one direction. The linkconveyor is moved by a roller track in this case. Only one, multiple orall rollers may be driven.

FIG. 3a shows a preferred transport unit according to the invention,comprising conveyor belt (7) (preferably a link conveyor as in FIG. 2),which is driven laterally by driving rollers (14) and is supported onsmall rollers (15) in the middle.

FIG. 3b shows a similar structure, in which conveyor belt (7) rests oncontinuous driving rollers (17) over its complete width. To achieve abetter frictional engagement between the driving rollers (14) or drivingcylinders (17) and the conveyor belt (7), pressing rollers (13) pressthe conveyor belt onto the driving rollers (14) or driving cylinders(17).

FIGS. 4a and 4b show a preferred structure according to the invention,in which the driving rollers (14) are driven by a shared driving belt(18). Conveyor belt (7) may then rest on the driving belt and beadditionally supported. In FIG. 4a , the middle of conveyor belt (7) issupported on sliding elements (19) made of, e.g., plastic. In FIG. 4b ,the middle of the conveyor belt is carried by air cushions (20).

FIGS. 5a through 5c show a structure according to the invention,comprising a link conveyor (7), which has a gripping element (22) oneach link. A gripper, which repeatedly grips and positions a grippingelement, passes beneath the link conveyor. The sequence is gripping andpositioning (FIG. 5a ), opening the gripper (FIG. 5b ), returning andregripping a link (FIG. 5c ).

FIG. 6 also shows a structure according to the invention, including alink conveyor (7), which has a gripping element (22) on each link,according to the invention. In this case, gripping elements (22) arepositioned by a rotating worm drive (24).

FIG. 7 shows an oblique view of a preferred feed system according to theinvention, including raised grates according to the invention.

FIGS. 8a through 8c show the sequence of the feed system from FIG. 7,from the front and from the side in each case, according to theinvention.

FIG. 8a shows the starting position when both lifting grate (26) andthrusting grate (27) carry the conveyor belt. In FIG. 8a , lifting grate(26) has been extended and thrusting grate (27) subsequently lowered.

In FIG. 8b , lifting grate (26) has been lowered so that only thrustinggrate (27) carries conveyor belt (7). Thrusting grate (27) then movesconveyor belt (7) into its next position.

In the lowered state, thrusting grate (27) returns to its startingposition, as illustrated in FIG. 8 a.

FIG. 9 shows a preferred structure according to the present inventionwith self-propelled building platforms (31). They are moved intobuilding device (32).

FIGS. 10a through 10c show additional preferred embodiments according tothe invention. In this case, the feedstock is not produced linearly butrotatorily. The process begins at a first position or end and ends at asecond position or end. FIG. 10b is a view of FIG. 10a from above. FIG.10c is a side view of FIG. 10b of the cone printer according to theinvention, on sectional plane A-A. (33) designates the outwardlyoriented movement of coater (1) and solidification unit (2), which isindicated using directional arrows, the method being carried out onbuilding platform (34), and a particulate material feedstock (3) beinggenerated and components [produced], e.g., component (5), followingsolidification. For this purpose, round building platform (34) isrotated, while coater (1) and the print axis move away from the rotationaxis. Coater (1) is rotated 90° with respect to the other preferreddevices of the invention described above and may be operatedcontinuously. Solidification unit (2) may also work continuously,whereby a plurality of components may be produced in this manner on onebuilding platform (34) in one operation (batch). A build cone (21) maybe used to start the system. The alpha angle may be changed, dependingon the particulate material, and thus be optimally adapted to theparticular particulate material used. This device type requires the datafor the molds for the components to be produced to be skewed not onlylinearly but also on the basis of polar coordinates. The dimensions ofthe cone printer and the building platform as well as the device as awhole may be selected in such a way that both very small and very largeand heavy components may be produced without distortion.

FIG. 11 shows a preferred building device (32) according to theinvention, to the end of which an unpacking area, including a rollertrack (35), is connected. The finished components are deposited directlyonto the roller track. Loose particulate material may run off betweenthe rollers and thus support unpacking. The roller track may be drivenor it may run passively.

FIG. 12 shows a preferred building device according to the inventionwith a rotating building platform (34). Coater (1) and solidificationunit (2) move only translatorily, while building platform (34) continuesto rotate layer by layer and thus continuously builds up materialfeedstock (3). In another preferred embodiment, the device in FIG. 12may be configured in such a way that it is combined with an unpackingstation or an unpacking operation in an arbitrary position. Finishedcomponents (5) are shifted to a position (36) inside or outside or belowor above building platform (34) and freed of the remaining looseparticulate material simultaneously or in another work step. The processbegins at a first position or end, e.g., at the point of the firstparticulate material application, and ends at a second position or end,e.g., upon completion of the component or preferably at the point ofunpacking. The loose particulate material may be resupplied cyclicallyto the further continuous process. The particulate material supply isthus limited to the quantities which are removed from circulation in theform of components and any non-reusable quantities.

FIGS. 13a through 13f show a drive for belts or link aprons with liftinggrates (26) and thrusting grates (27) according to the principle of thestep conveyor. Thrusting grate (27) moves on lever arms which swivelback and forth. Lifting grate (26) is raised on the return swivelingmotion.

FIGS. 14a through 14d show a drive for belts or link aprons with liftinggrates (26) and thrusting grates (27) according to the principle of thestep conveyor. Thrusting grate (27) moves on rotating lever arms.

FIGS. 15a through 15d show a drive for belts or link aprons with liftinggrates (26) and thrusting grates (27) according to the principle of thestep conveyor. A vertical lifting of lifting grate (26) alternates withan inclined lifting of thrusting grate (27).

LIST OF REFERENCE NUMERALS

-   -   1 Coater    -   2 Solidification unit    -   3 Powder cake/particulate material feedstock    -   4 Tunnel wall    -   5 Component (being built)    -   6 Roller for cover belt    -   7 Conveyor belt (e.g., link conveyor)    -   8 Linear unit    -   9 Build space    -   10 Link with hinge    -   11 Driving cylinder    -   12 Cylinder bearing    -   13 Pressing roller    -   14 Driving roller    -   15 Bearing roller    -   16 Motor    -   17 Conveyance direction    -   18 Driving belt (e.g., toothed belt)    -   19 Sliding element    -   20 Air cushion    -   21 Gripper    -   22 Gripping element    -   23 Linear feed    -   24 Worm wheel    -   25 Frame    -   26 Lifting grate    -   27 Thrusting grate    -   28 Linear bearing    -   29 Lifting unit for lifting grate    -   30 Lifting unit for thrusting grate    -   31 Self-propelled building platform    -   32 Building device    -   33 Direction of movement of the coater and the solidification        unit    -   34 Rotating building platform    -   35 Roller track    -   36 Unpacking area    -   37 Edge of tunnel wall    -   38 Entry opening of the tunnel

What is claimed is:
 1. A device for producing three-dimensional modelscomprising: a tunnel; a conveyor for moving a feedstock including thethree-dimensional model through the tunnel, wherein the conveyor isdriven in a conveyance direction; and a coater that applies a layer ofloose particulate material directly onto the feedstock at an entryopening to the tunnel and moves on linear guides for applying anadditional layer of particulate material onto the feedstock, wherein thelinear guides are outside of the tunnel; wherein a portion of theparticulate material in the feedstock forms the constructedthree-dimensional model and a portion of the particulate material in thefeedstock remains loose particulate material.
 2. The device of claim 1,wherein the tunnel includes upright side walls.
 3. The device of claim1, wherein the coater moves along the linear guides in an inclineddirection.
 4. The device of claim 1, wherein the feedstock substantiallyfills the entry opening.
 5. The device of claim 1, wherein the devicehas an unpacking region where the loose particulate material isextracted or removed from the feedstock.
 6. The device of claim 1,wherein the tunnel at least partially supports the feedstock.
 7. Thedevice of claim 1, wherein the tunnel at least partially supports thefeedstock.
 8. A device for producing three-dimensional modelscomprising: a tunnel; a conveyor for moving a feedstock including thethree-dimensional model through the tunnel, wherein the conveyor isdriven in a conveyance direction; and a coater that applies a layer ofloose particulate material directly onto the feedstock at an entryopening to the tunnel, wherein the coater is positioned outside of thetunnel; wherein in the coater applies the particulate material onto asurface of the feedstock that has an angle of greater than 0° relativeto a plane of the conveyor below the feedstock.
 9. The device of claim8, wherein the device includes a print head or a laser for selectivelysolidifying the particulate material.
 10. A device for producingthree-dimensional models comprising: a tunnel; a conveyor for moving afeedstock including the three-dimensional model through the tunnel,wherein the conveyor is driven in a conveyance direction; and a coaterat an entry opening to the tunnel, wherein the coater applies aparticulate material in layers to the feedstock wherein each layer isangled relative to the conveyor, and each layer enters the tunnel afterbeing applied; wherein the coater is positioned outside of the tunnel.11. A method for building a three dimensional object using the device ofclaim 10, comprising the steps of: i) applying a layer of looseparticulate material on a surface of a feedstock material at an entryopening to a tunnel using a coater positioned outside of the tunnel; andii) conveying the feedstock material through the tunnel.
 12. The methodof claim 11, wherein the feedstock substantially fills the entirety ofthe entry opening.
 13. Then method of claim 12, wherein the methodincludes selectively solidifying the particulate material using a laseror print head.
 14. The method of claim 13, wherein the applied layers ofparticulate material are angled relative to the conveyor.
 15. The methodof claim 14, wherein the method includes conveying the feedstock out ofthe tunnel and removing loose powder and unpacking the three-dimensionalobject.
 16. The method of claim 15, wherein the conveyor is astep-conveyor.
 17. The method of claim 16, wherein the conveyor moves ata transfer speed of 0.5 to 20 m/min.
 18. The method of claim 11, whereinthe conveyor moves in a horizontal direction and the coater is mountedon linear guides which are angled relative to the horizontal, whereinthe angle between the linear guides and the horizontal is greater than 0degrees and less than 30 degrees.
 19. A device for producingthree-dimensional models comprising: a tunnel; a conveyor for moving afeedstock including the three-dimensional model through the tunnel; anda coater that applies a layer of loose particulate material directlyonto the feedstock prior to the layer entering the tunnel, wherein thelayer is on a plane having an angle greater than 0 degrees relative tothe conveyor; wherein a portion of the particulate material in thefeedstock remains loose particulate material; and wherein a wall of thetunnel is inclined to form a tunnel opening parallel to the plane. 20.The device of claim 19, wherein the coater is outside the tunnel.